HINDUSTAN PETROLEUM CORPORATION

LTD.
(A Government of India Enterprise)


RKPL PROJECT (FOR TERMINALS)


BID DOCUMENT

FOR

Supply of ROSOV

PUBLIC INTERNATIONAL COMPETITIVE BIDDING


VOLUME II of II

BID DOCUMENT NO. 13000121-HD-10129














13000121-HD-10129 1 of 57



SPECIFICATIONS FOR REMOTE OPERATED
SHUTOFF VALVES (ROSOV)

TRIPLE OFFSET, DOUBLE FLANGED ,

BUTTERFLY VALVES WITH FAIL SAFE ELECTRO HYDRAULIC AND
PNEUMATIC ACTUATORS















13000121-HD-10129 2 of 57

List of Content

1 Introduction
1.1 Definitions
2 Applicable Codes, Specifications and Standards

2.1 General
2.2 Deviations to Specification
2.3 Conflicting Requirements
2.4 Abbreviations &Terminology

3 Product Details Plant Environmental Conditions
4 Hazardous Area Classification and Protection
5 Utilities Specification
6 Scope of Supply
7 Specifications & Documents attached
8 Technical
8.1 Design & Construction
8.2 Materials &Test Procedures
9 Pneumatic Actuators for Shutdown Application
9.1 General
9.2 Accessories (all actuators)
9.3 ROSOV Operation
10.0 Inspection and Tests
10.1 General
10.2 Actuator
10.3 Test Certificates
11.0 Spares &Accessories
12 Documentation Guarantee

14.0 Site Service/Site Visits by Experts.
15.0 Painting, Marking and Shipment// Storage DATA Sheets- Valve, Actuator, Solenoid
Valve




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1 I ntroduction

Hindustan Petroleum Corporation Limited (HPCL) proposes to procure Remote Operated Shut Off
Valve (failsafe) with electro hydraulic actuators for Bharatpur location and ROSOV with pneumatic
actuator for Mathura location.

The purpose of this specification is to define the requirements for pneumatic actuated on/off shut
down valves for the following services-

Tank Overfill Protection Shutdown via Emergency Shutdown System with use of (ROSOVs)
pneumatically remotely operated valves from ESD (SIS) System.
Overfill protection system shall be de-energized to trip. Solenoid Valve of ROSOV shall be SIL2
Certified and operate on 230V AC.

This specification covers the minimum requirements for the design, manufacture, assembly,
Inspection, testing, certification & delivery of On-Off type Triple Offset Butterfly Valves with Electro
hydraulic and Pneumatically operated actuator complete with all accessories, for HPCL Bharatpur
and Mathura Locations as per following.

Group Location Item no Descrption Unit Qty
A Bharatpur
A1
Supply of 12 inch ROSOV with
Electrohydraulic actuator
Each 1
A2
Supply of 10 inch ROSOV with
Electrohydraulic actuator
Each 9
A3
Supply of 8 inch ROSOV with
Electrohydraulic actuator
Each 16
A4
Supply of 6 inch ROSOV with
Electrohydraulic actuator
Each 4

B Mathura B1
Supply of 18 inch ROSOV with
Pneumatic actuator
Each 2



1.1 Definitions
Owner : Hindustan Petroleum Corporation Ltd

Bidder / Manufacturer Valve Manufacturer


Engineer In- charge Means the Resident Engineer or a person acting on behalf of
HPCL at site

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Shall : This is to be understood as a mandatory in relation to the requirements
of this Document.

Should : This is to be understood as a strong recommendation to comply
with the requirements of this document.

2 Applicable Codes, Specifications and Standards

2.1 General

2.1.1 The items shall be designed and supplied in accordance with this Specification and the codes
and standards referenced herein. The design, manufacture, assembly, inspection, testing and
certification of Pneumatic Operated on off type triple offset high performance butterfly valves
shall be in accordance with the latest edition of the codes including amendments, specifications and
standards (including standards / specifications mentioned therein )listed in this requisition.

API598 2004 Valve Inspection and Testing
API-6FA 1999 Specification for Fire test for Valves.
API607 2005 Fire test for soft-seated quarter-turn valves
API609 2009 Butterfly Valve Design
ASMEB1.20.1 1983 Pipe Threads, General Purpose(inch)
ASMEB16.5 2003 Steel Pipe Flanges and Flanged Fittings
ASMEB16.10 2000 Face-to-Face and End-to-End Dimensions of Valves
ASMEB16.34 2004 ValvesFlanged, Threaded, and Welding End
ASMEB31.3 2004 Chemical Plant and Petroleum Refinery Piping
ASMEB31.4 2004 Liquid transportation systems for hydrocarbons and other liquids
ANSIB46.1 1995 Surface Texture(Surface Roughness, Waviness & Lay)
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BSEN12266
Part2
2002 Industrial Valves, Testing of valves, test procedures &
Acceptance criteria.
EN50018 2000 Electrical Apparatus for Potentially Explosive
Atmosphere [EEx(d)]
IEC60079 2006 Electrical apparatus to explosive gas atmosphere.
IEC60529

2004 Classification of degrees of protection provided by
Enclosures (IPcodes).
IEC60801 1991 Electromagnetic compatibility of Industrial-Process management and
control equipment
IEC61508
Functional
2010 Safety of Electrical/Electronic/ Programmable Electronic Safety Related
Systems
IEC61511 2010 Functional safetySafety Instrumented Systems for the Process Industry
Sector
MSS-SP-61 2003 Pressure Testing of Steel Valves
SSPC-VIS-1 2002 Steel structures painting council-visual standard
IS-2148 2004 Flame-proof enclosures for electric apparatus, etc:
IS-1271 1985 Methods for determining thermal classification of electric insulation.

2.2 Deviations to Specification

2.2.1 The Bidder shall provide an itemized list of any deviations to this specification. These shall be
listed on the Compliance sheet with seal & duly signed by authorized signatory & shall be
submitted along with offer by the Bidder.

2.2.2 Where conflict between standards occurs then the Bidder shall seek a clarification ruling from
the Owner. Where a deviation from the standard is required, then the Bidder shall make
formal request with full supporting information.

2.2.3 Only those deviations that are agreed between the Owner and the Bidder will be incorporated
in to the requisition at the time of order.

2.3 Conflicting Requirements

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In case of conflict between the requirements of this specification, API609 and the Codes, Standards
and Specifications referred in clause 2.1 above, the requirements of this specification shall govern.
Order of precedence shall be as follows:

First priority - Data Sheets
Second priority - This Specification
Third priority - API 607 609
Fourth priority - Other Referred Codes &Standards
Fifth priority - Manufacturers Standard
Note: Should any conflict arise either before or after order placement the Bidder shall immediately
inform the Owner for technical resolution of the conflict

2.4

Abbreviations &Terminology
CE Carbon Equivalent
DVC Digital Valve Controller
ESDV Emergency Shutdown
valve FAT Factory Acceptance Test
FB Full Bore
FC Fail Safe Close
FMEDA Failure Modes Effects and Diagnostic
Analysis. FO Fail Safe Open
GUI Graphical User Interface

HFT Hardware Fault Tolerance
MOV Motor Operated/ Actuated On-Off Valve
IEC International Electro-technical
Commission IS Intrinsic Safety
ISA Instruments Society of America
J B J unction Box
LO Lock Open/ Full
Open LC Lock
Close/ Full Close LSS
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Long Standing Still
MOS Manual Override Switch
MOV Motor Operated Valves
MSBT Maximum Spring Break
Torque MTBF Mean Time Between Failures
MTTR Mean Time To Repair
PFD Probability of Failure on Demand
PST Partial Stroke Testing
PSTD Partial Stroke Testing Device

QAP Quality assurance Plan
RC Regular Cycling
ROSOV Remote OperatedESDV
SAT Site Acceptance Test
SFF Safe Failure Fraction
SET Spring End Torque
SIL Safety Integrity Level
SIS Safety Integrated Systems
SOV Solenoid Operated Valve
SRT Spring Return Torque
SST Spring Standing Torque
TAS Terminal Automation System
TFMS Tank Farm Management System
TOBV Triple Offset High Performance Butterfly Valves.
VAC Volts alternating current
VDC Volts direct current
CCOE Chief Controller Of Explosives
CMRI Central Mining Research Institute


3 White Oil product details
In the table below, Product Characteristics of the products are mentioned as general guidelines to
bidders

Product


Flash
point
(OC)


Specific
gravity
gm/cc

Vapour pressure
kg/cm2a



Viscosity
(cSt)
Pumping Temp. (OC)


HSD -
High
Speed
>35

0.82-0.86

<0.4

2-5 @ 40OC

Ambient

Diesel
MS -
(-) 30

0.73

0.7

<0.7

Ambient

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Motor
Spirit
Naphtha

(-) 20

0.69- 0.78

<0.7


<0.7

Ambient



ATF -



>35



0.8



<0.4




2.56



Ambient

Aviation

Turbine
Fuel
101

Ambient

SKO -
Super
Kerosene
Oil


>35


0.8


<0.05


1.97


Ambient

MTO -
Mineral
Turpentine
Oil



33



0.82



0.01


14.92




Ambient

Hexane

(-) 23.3

0.66

0.37 0.277 Ambient

Ethanol 16.6 0.79

0.08

1.2

Ambient


The above product specifications are indicative and may vary.

4 Hazardous Area Classification and Protection

4.1 Instruments located in hazardous area shall be certified to meet or exceed the electrical
hazardous area defined by Area classification

4.2 The actuator accessories used shall be flame proof and suitable for hazardous area of
Zone1,Group IIA/IIB,T3 or better for applications. Additionally all valve associated instruments
shall be weather proof to IP65 as minimum. Instruments certified for use in the specified
hazardous area classification shall have certifications/ approvals from accredited international
agencies like FM, ENELEC, PTB, BASSEFA, ATEX, etc.
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All enclosures for electrical equipment shall be suitable for use in Hazardous are as per Haz. Area
Classification and vendor shall submit valid test certificate issued by CIMFR & PESO. Flameproof
enclosures and instruments which are manufactures outside India and certified by accredited
international authorities shall also have approval of PESO, India.

5 Utilities Specification

5.1 Instrument Air Supply pressure may range between 4.5kg/cm(g) to 6.5kg/cm(g). However
Actuator shall be sized for instrument air supply pressure of 4.0kg/cm2 (g) & shall withstand the
design pressure 10kg/cm2(g).

5.2 Electric Supply of 230 V (+/- 10%) AC, 50 HZ (+/- 5%)

6 Scope of Supply

6.1 The scope of this tender covers the design, manufacture, testing and supply of electro hydraulic
and pneumatically actuated, failsafe to close valves to be installed on the tank body of
petroleum storage tanks as per the specifications and data sheets attached. These valves are
part of SIS for tank overfill protection & functioning as ROSOVs(ESDVs).

Complete actuated valve assembly shall have capability for use in SIL 3 application having
certification from TUV / Exida as per IEC 61508. However the designed SIS loop has one ROSOV
& as per IEC 61508, the architectural constraint limits overall loop SI to SIL2.

6.2 This specification covers the minimum requirements for design, manufacture and supply of fire
safe, triple offset ,metal to metal seated, high performance, bidirectional- zero leak tight
shutoff, non-rubbing, torque seated, antistatic, anti-blow out stem arrangement, quarter turn,
double flange end butterfly valves of size equal& more than DN 100 mm (4") to DN 700 mm
(28) as a complete assembly of valve & actuator unit with all accessories.

6.3 The materials, design and workmanship shall satisfy the relevant standards, specifications &
codes referred in this document. Where the specifications stipulate requirements in addition to
those contained in the standard, codes and specifications, these additional requirements shall
also be satisfied.

6.4 The Bidder shall supply the complete assembled and tested valve with actuator & related
accessories. The designed, engineered and supplied equipment/ system shall be suitable for the
site conditions specified. All components/consumables used shall be new, state of the art and of
current manufacture.

6.5 Bidder shall include in the bid, list of specific deviations, separately, if any, to this specification
and all attachment thereof, otherwise, the offer will be deemed to be in compliance with
complete tender and its attachments and subsequent claims for extra scope will not be
considered.

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6.6 This specification does not relieve the Bidder from final guarantee as to materials, apparatus,
workmanship and performance of the valve supplied.

6.7 The Bidder shall, in respect of this tender, procure material from approved makes/vendors listed
in the datasheet notes, unless the particular type of material is not covered by the list, or a
special dispensation to deviate from the list has been granted in writing by the Owner.

6.8 Vendor / Bidder to include the startup & commissioning spares for valves, actuators and other
accessories in the quoted price and the list of such spares shall be provided in the technical bid.
6.9 Deleted.

6.10 Approved vendor/ makes are provided in this tender is for the manufacturer name only, and
not for any specific model. For all items/components the offered model must meet the relevant
specification and proven track record (PTR) requirements as specified in this tender document.
The Bidder shall provide the related necessary evidence for use of their valves in similar
application (reference lists with installation dates and run hours accumulated by date, etc.).
Only equipment of proven reliability in similar service conditions, shall be included in the
Bidders proposal (prototypes shall not be proposed).

6.11 Bidder shall prepare and submit all necessary documents during various stages of the project
as listed in this tender document.

6.12 Inspection and testing of all components, sub-assemblies and complete assemblies of items
manufactured at Bidders works, and other sub-Vendors/Suppliers Bidders works shall be in
accordance with approved QA/QC procedure.

6.13 Factory Acceptance Test (FAT) shall be performed in line with tender requirements & as per
approved post PO FAT procedure . Providing necessary manpower & equipment support during
FAT/ testing is in bidders scope.

Specifications & Documents attached

7.1 Specification, datasheets, schedule of quantities for valves are appended to the specification.

Technical

8.1 Design & Construction of Triple Offset High Performance Butter fly Valves

8.1.1. Metal seated butterfly valve shall be supplied with anti-static devices.
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8.1.2. Butterfly valves shall be as per API 609 with double flange ends construction.

Dimensions shall be as per API 609 long pattern.

8.1.3. Flanged end shall have dimensions as per ASME B16.5 .

8.1.4. Flange face shall be raised face. Flange face finish shall be serrated or smooth as indicated in
Valve Data Sheet. Smooth finish when specified shall be 63-125AARH smooth finish.

8.1.5. When specified in the valve data sheet, valves shall be designed to withstand a sustained
internal one milli bar vacuum in both open and closed position.

8.1.6. Valves shall be provided with position indicator and stops at the fully open and fully closed
positions.

8.1.7 Manufacture unit shall be in possession of valid ISO 9001 certificate

8.1.8 Valve should meet ISO 15848 standard for fugitive emissions

8.1.9 Vendor will indicate closing torque required for each size of the valve for their closing. Valve
will be pressure tested at closing torque and should achieve zero leak .

8.1.10 Valve shall be manufactured with close tolerance and should employ robotic welding and 3D
measurement of seat and disc .

8.1.11 Valve body to be in single piece and valve seat disc should not protrude out side the valve
body upto 20 size.

8.1.12. Valves of size DN 200 mm (8) and above shall be equipped with lifting lugs. Tapped holes
and eye bolts shall not be used for lifting lugs. Incase lifting lugs are not provided on the
valve then vendor shall provide detailed instruction set for handling the valves for installation
without need of lifting lugs.

8.1.13 Valves shall be of fire safe design as per BS EN 12266 Part2 /API6FA/ API607,as indicated in
Valve Data Sheet. As a special requirement one valve for each size selected randomly by TPI
shall be fire tested as per the specifications at the manufacturers place over and above the
requirements specified in the API standards.

8.1.14 Valves shall be suitable for above ground installation as indicated in the Valve Data Sheet.

8.2 Materials & Test Procedures

8.2.1 Material for major components of the valves shall be as indicated in Valve Data Sheet.
8.2.2 Carbon steel used for the manufacture of valves shall be fully kilned.
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8.2.3 The Carbon Equivalent (CE)of valve end connections, shall not exceed 0.45% (as calculated by
the following formula) on check analysis for each heat of steel used:



8.2.4 Charpy V Notch test on each heat of base material shall be conducted as per API609, for all
pressure containing parts such as body, end flanges and welding ends as well as bolting
material for pressure containing parts. Unless specified otherwise, the Charpy impact test shall
be conducted at 0C. The Charpy impact test specimen shall be taken in the direction of
principal grain flow and notched perpendicular to the original surface of plate or forging.

8.2.5 The minimum average absorbed energy per set of three specimens shall be 27J with an
individual minimum per specimen of 22J . No specimen shall exhibit less than 80 per cent
shear area.

8.2.6 The hardness of base material of body and principal parts of the valve such as disc & body etc.
shall not exceed 22RC. Shaft/ Stem can be with higher hardness based on the shaft material &
applicable relevant standard.

9 Pneumatic Actuators for Shutdown Application

9.1 General


9.1.1 Single actingspring return pneumatic piston actuators of scotch & yoke type as specified in
data sheet shall be used for shutdown services and where the valve design dictates. Rack &
Pinion & Pressure balance actuators shall not be used.

9.1.2 These ROSOVs shall be equipped with spring return single acting piston actuators.

9.1.3 The required position of the valve when the controlling medium is lost shall be Fail Closed as
indicated on the datasheets.

9.1.4 The actuator shall be sized using a factor of 1.25times the maximum shut-in head pressure to
ensure that the actuator has sufficient built-in power to operate the valve from a closed in
system or to ensure seating against such a condition.

9.1.5 The actuator-valve stem connection shall be a bolt-threaded split clamp.

9.1.6 Piston actuators shall be sized to provide the required force at supply pressure of 4.0
13000121-HD-10129 13 of 57
kg/cm(g) but must be suitable for pressures up to 10.0kg/cm(g).

9.1.7 Where requested on data sheet the actuator shall be supplemented with air capacity tanks
(with non-return valves, pressure gauges, drains etc.). Air capacity tanks shall be sized to
provide adequate air storage such that three valve operations may be obtained between 4.0
and 6.5 kg/cm. The tanks shall be manufactured from carbon steel, painted and shall be to
the pressure vessel code applicable to the project.

9.1.8 All tubing shall be 316 Stainless Steel and in imperial sizes. Permissible OD/ wall thickness
shall be as follows:
"ODx0.049"wallthickness

9.1.9 Actuator colors shall be: RAL3001 Signal Red for Fail Close ROSOVs.

9.1.10 These ROSOVs will be used as tank body ( inlet/outlet) isolation with shutdown application
for tank overfills protection. Bidder shall have the ROSOVs with actuator installed in
90Deg. angle with nozzle/ pipeline axis.

9.2 Accessories

9.2.1 Accessories such as solenoid valves, AFRs etc., shall be procured and mounted by Bidders
Local Station in a field mounted cabinet. External tubing connection shall be either "O.D.
Instruments shall be tropicalized for humidity and fungus and shall be termite resistant, IP65
classification. Bidder shall be completely responsible for the Functioning of the control scheme
as per data sheet requirements.

9.2.2. Solenoid valves shall be certified EExd (except when data sheet calls for EExi) coil rating
230V AC. Integral terminals shall be provided for the termination of cabling. Flying leads from
the coil enclosure shall not be used. Pneumatic solenoid valves shall be constructed of
stainless steel body, stainless steel trim and SS enclosure. Zero copper aluminium enclosures
with two pack epoxy finish are acceptable.

9.2.3. The pneumatic actuator shall be fitted with micro switches as limit switches, one at the
open and one at the closed position. The switches shall operate at less than 5% of the
valve travel from their respective limits.

9.2.4. Limit Switches should be EExd. Bidder shall supply full technical specification of the switches
in his offer. Switches shall be pre-cabled to a junction box mounted on the actuator using
NPT metallic glands.

9.2.5. J unction boxes shall be made from stainless steel, environmentally rated IP65 and certified
EExd for use in Zone1 hazardous areas as standard. Cables shall be clearly identified at both
ends using securely fitted PVC cable markers. All cable cores and wiring shall be fitted with
core identification ferrules at each end. All cores shall be terminated in terminals.

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9.2.6 All tube bending shall be carried out cold by gradually applied pressure using an approved
type bending machine. Bending shall not include hammering or the application of any force
which may damage the tube. Tube cutting shall be executed using an approved type tube
cutter, saw cuts are not to be made. After cutting the ends shall be dressed with the
appropriate belling tool to ensure that a restriction has not been introduced. Prior to
installation, the tubing shall be internally cleaned, degreased with a suitable solvent and then
dried.
9.2.7. All actuators/ valves shall be fitted with a permanently attached stainless steel labels

(not wired-on) showing as a minimum the following information:

Bidders name & OEM name

Model & serial numbers

Instrument tag number

Manufacturers standard data

Position on actuation medium failure

Materials of construction of valve body

Pressure and temperature ratings(valve only)

9.2.8. Fireproofing of actuator is not envisaged.

9.2.9. All accessories mounted on valve assemblies shall be capable of withstanding line vibrations &
surge.



9.3 ROSOV Operation

9.3.1. ROSOVs are part of SIS which consists of SIL3 ESD Safety PLC, SIL2 capable High
Level Switch/ any other input element & ROSOVs as final control element.

9.3.2. Each ROSOV shall be with Emergency Close (Shut-off) Local Station which shall be located
outside the dyke which is 20mtrs minimum from the ROSOVs.

9.3.3. Emergency Shut-off Local Station shall be made from LM-6 & having valid CCOE approval.
Controls shall be mounted on front & shall be protected against inadvertent operation.

9.3.4. ROSOV Operation will be as follows:-

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a. The valve can be closed from the Local Station for Close Control. No mechanical manual overrides
, lock out devices or by-passes are permitted.

b. In addition to SIS functionality, the ROSOV can be closed from the control room either from ESD
push button or through all operator interface stations for Operators interaction with ESD safety
PLC system(SIS) via the Graphical User Interface(GUI) facilities of the Terminal Automation
System, wherever provided, with access control & security levels defined.

c. A dedicated ESD graphics screens showing the status of each SIS connected equipment shall be
developed by Terminal Automation System (TAS) vendor.

9.3.5. To reset , the system must be reset from the Emergency Reset station in control room or
through TAS Operator Interface

10.0 Inspection and Tests

10.1 General

10.1.1 The Manufacturer shall perform all inspection and tests as per the requirements of this
specification and the relevant codes, prior to shipment, at his works. Such inspection and
tests shall be, but not limited to the following:

10.1.2 All valves shall be visually inspected. Dimensional check on all valves shall be carried out as
per the Owner approved drawings. Owner shall have the right to inspect/witness the tests.

10.1.3 An indicative QAP has been furnished in the tender document. The bidder shall develop
further this QAP based upon the specifications in the tender & submit the same for approval.

10.1.4 Acceptance of the materials shall be subject to inspection, approval and release by the
inspection agency designated by Owner. Inspection will be carried out as per the scope of
inspection detailed in this specification and as per the relevant standard, for which all
arrangements/ facilities shall be made by successful bidder.

10.1.5 Painting shall be in line with Painting specifications.

10.1.6 Test certificates should make specific mention that the valves conform to its relevant
Standard. It should also include the date of manufacture and surface preparation/ painting.

10.1.7 Chemical composition and mechanical properties shall be checked as per relevant material
standards and this specification, for each heat of steel used.

a) Non-destructive examination of individual valve material and components consisting of, but not
limited to castings, forgings, plate and assembly welds shall be carried out by the Manufacturer.

13000121-HD-10129 16 of 57
b)Body castings of all valves shall be radio-graphically examined on 100% of the surface of critical
areas as per ASME B16.34. Procedure and acceptance criteria shall be as per ASME B16.34.

10.1.8 All valves shall be tested in compliance with the requirements of API598/ API609.
During pressure testing, valves shall not have sealant lines and other cavities filled with
sealant , grease or other foreign material. The drain ,vent and sealant lines shall be either
included in the hydrostatic shell test or tested independently. No leakage is permissible
during hydrostatic testing.

The body cavity self-relieving feature meeting the requirements of this specification shall also
be checked.

10.1.9 A supplementary air seat test as per API609 shall be carried out for all valves.

a. A bubble tight seal is required without the use of any sealant. No leakage is allowed. Test
pressure shall be held for at least15minutes.

b. Valves shall be subjected to Operational Torque Test as per supplementary test
Requirement of API609 under hydraulic pressure equal to maximum differential pressure
corresponding to the valve rating.

c. Valves shall be subjected to anti-static testing as per supplementary test requirement of
API609.

10.1.10 10% of valves for each size shall be tested after assembly of the valve and actuator at the
valve Manufacturers works. At least five open-close- open cycles without internal pressure
and five open-close-open cycles with maximum differential pressure shall be performed on
the valve actuator assembly. The time for full open to full close shall be recorded during
testing. If required, the actuator shall be adjusted to ensure that the opening and closing
times are within the limits stated in Actuator Data Sheet issued for the purpose.

10.1.11 In case the tests do not meet the requirements, retesting/rejection of the lot shall be
decided by Owners Inspector.

10.1.12 Owner reserves the right to perform stage-wise inspection and witness tests as indicated
above at Manufacturers works prior to shipment. Manufacturer shall give reasonable access
and facilities required for inspection to the Owners Inspector.

10.1.13 Owner reserves the right to require additional testing at any time to confirm or further
investigates a suspected fault. The cost incurred shall be to Manufacturers account. In no
case shall any action of Owner or his Inspector relieve the Manufacturer of his responsibility
for material, design, quality or operation of valves.

10.1.14 Inspection and tests performed/ witnessed by the Owners Inspector shall in no way relieve
the Manufacturers obligation to perform the required inspection and tests.
13000121-HD-10129 17 of 57

10.2 Actuator

For ROSOVs the following tests shall be provided prior to shipping:

Actuator operation, Cycle (open-close) each valve with its actuator at least five times, for proper
actuator operation. Verify that valve position coincides with position indicators.

Opening-closing position

Actuator output speed & Open-Close time

Actuator travel setting

Operational torque test as per API609.

10.3 Test Certificates

10.3.1 Manufacturer shall submit the following certificates:

a)Mill test certificates relevant to the chemical analysis and mechanical properties of the materials
used for valve construction as per the relevant standards.

b)Test certificates on hydrostatic and pneumatic tests complete with records of timing and pressure
of each test.

c)All other test reports and certificates as required by API598/ API609 and this specification. The
certificates shall be valid only when signed by TPI. Only those valves which have been certified by
Owners Inspector shall be dispatched from Manufacturers works.

11.0 Spares & Accessories

11.1 Manufacturer shall furnish list of recommended spares and accessories for valves required
during start-up and commissioning.

11.2 Manufacturer shall furnish list with price of recommended spares and accessories required for
two years of normal operation and maintenance of valves.

12 Documentation :
All documents shall be in English language.

12.1 Documentation with offer:
Bidder shall submit the following documents along with offer:

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12.1.1 General arrangement/ assembly drawings showing all features and relative positions and
sizes of vents, drains, actuator, painting, coating and other external parts together with over
all dimensions along with weight, air consumption, minimum air pressure requirement
&opening-closing time.

12.1.2 Sectional drawing showing major parts with reference numbers and material specification. In
particular, a blow-up drawing of disc seat assembly shall be furnished complying the
requirement of this specification.


12.1.3 Sizing calculations for selected actuator. Torque curves for the actuators along with the break
torque and maximum allowable stem torque. In addition, sizing criteria and torque
calculations shall also be submitted for actuated valves.

12.1.5 As a mandatory requirement, Bidder shall firm up the Make &Model of actuator, other
accessories like limit switches, SOV, AFR, etc.at the time of submission of bids & same shall
not be changed after PO placement. Bidder shall submit de-codification sheet for each type
and size for valve and actuator along with torque value .

12.1.6 Descriptive technical catalogues of the Manufacturer.

12.1.7 Details of support foot, including dimensions and distance from valve centerline to bottom of
support foot

12.1.8 Manufacturer who intends bidding, must submit at bid stage, certificate report for successful
fire type-tests for valves in accordance withAPI-607/ BS EN 12266(Part 2)/ API6FA, as
applicable in Valve Data Sheet along with copy of valid API-609 Certificate. Failure to comply
with this requirement shall be a cause of rejection of the offer.

12.1.9 Details for calculating overall Safety Instrumented Systems SIL assessment which requires
inputs from each SIS device manufactures who contributes in SIF like Initiators, Logic Solver
& Final Control element, hence it is implied on actuated valve OEM to provide all necessary
information viz SIL Certification, Functional Safety Manual, PFDAVG, SFF, TProof,, NE, S, D for
individual devices of actuated valve & then complete package i.e. full actuated valve.

12.1.10 Details of manufacturing / testing facilities available with the bidder and rated production
capacity.

12.1.11 Detailed bar chart showing different stages of design, manufacture, testing and dispatch
schedules.

12.1.12 Deviations from specifications and attachments if any.

12.1.13 QAP formats duly filled and signed.

12.1.14 Confirmation regarding the codes & standards specified for different works.

13000121-HD-10129 19 of 57
12.1.15 List of recommended spares and accessories for valves &actuators for startup &
commissioning.

12.1.16 List of recommended spares and accessories for valves & actuators for 2(two) years normal
operation.

12.1.22 Guarantee for performance, workmanship & materials of construction.

12.2 Documentation after Purchase Order placement:

12.2.1 Within three weeks of placement of order, the Manufacturer shall submit six copies of, but
not limited to the following drawings/ documents for Owners approval:

a) Sizing of actuator & selected model for approval.

b) Detailed sectional arrangement drawings showing all parts with reference numbers and material
specifications.

c) Assembly drawings with overall dimensions and features.

d) Hazardous area classification for valve accessories, electrical power consumption for each type
and size of valve for approval

e) Installation requirements

f) QA plan for approval
Manufacture of valves shall commence only after approval of the above documents. Once the
approval has been given by Owner, any changes in design, material and method of Manufacture
shall be notified to Owner whose approval in writing of all changes shall be obtained before the
valve is manufactured.

12.2.2 Manufacturer shall submit one reproducible and six copies of the following:

a) Test certificates as specified in specification. Inspection certificates & test reports shall be
supplied for all mandatory test as per the applicable codes.

b) Manual for installation, erection, maintenance and operation instructions, including a list of
recommended spares for the valves.

c) Details of corrosion resistant paint to be applied on the valves.

12.2.4 Material test and analysis certificates (physical properties, chemical composition & heat
treatment report) shall be furnished for the valves supplied. Material test certificates for other
parts shall also be furnished during inspection.

12.2.6 Other relevant information/drawings/ documents as required by Owner.

13000121-HD-10129 20 of 57
12.2.7 All the above documents shall be in addition to those mentioned in individual specifications of
valves.

12.3 Documentation & Drawings:
Six sets of final documentation shall be submitted in hardcopy and softcopy.

12.3.1. General arrangement/ assembly drawings showing all features and relative positions and
sizes of vents, drains, actuator, painting, coating and other external parts together with over
all dimensions, Sectional drawing showing major parts with reference numbers and material
specification , In particular a blow-up drawing of Disc-seat assembly.

12.3.2. Sizing of actuator & selected model with torque details for valves & actuators

12.3.3. Overall general arrangement and dimensional cross sectional drawings of valves, showing
part list, material list, weights etc.

12.3.4. Actuator Make, Model, details of selection based on torque, air & electrical power
consumption for each type and size of valve.

12.3.5. Inspection certificates & test reports shall be supplied for all mandatory test as per the
applicable codes.

12.3.6. Operation and maintenance manual.

12.3.7. Installation requirements.

12.3.8. Calibration certificates, Technical catalogue for valves, actuators & all accessories mounted
on valve.
13.0 COMMISSIONING ASSISTANCE & WARRANTIES AND TRAINING:

13.1 Vendor shall depute his commissioning engineer to all locations as covered in Purchase order
for commissioning supervision of valves and actuators & stabilization of valve & actuators
operations without any extra charges. The representative shall ensure that the actuator is
commissioned successfully. All expenses for site services shall be borne by
manufacturer/vendor bidder.

13.2 Vendor shall provide warranty for the performance of valves for 18 months from date of
dispatch or 12 months from date of installation, whichever is later subject to not exceeding 24
months from date of dispatch.

13.3 Manufacturer shall have / develop adequate service support in India to provide technical after
sales service in India with in 48 hrs. Notice & shall guarantee supply of parts, services for at
least 10 years for all valves supplied by way of an undertaking.

13.4 Site training ( At Owner works) : The scope of work of vendor shall include co-ordination,
13000121-HD-10129 21 of 57
arranging faculty, bring them to Owner's training center, arranging lodging and boarding,
transportation etc. for Training of Owner's personnel. Owner's responsibility will be limited to
providing Training hall with all requisite training aids and arranging food / snacks during
training session.

The training program will comprise of classroom training and explanation of details of valves.
The group to be trained will comprise of persons from all disciplines of maintenance, operation
and other associated departments.

The specialist installation / commissioning engineer(s) of valves will conduct the training
covering operational and maintenance aspects.

Training shall be arranged for Multidisciplinary group. Vendor shall arrange to provide one day
trainings at site engineers / operators on operations & maintenance of valves. (One day
Training at 10 locations in India for 12-15 persons each)

13.5 Deleted.

13.6 Manufacturer shall guarantee that the materials and machining of valves and fittings comply
with the requirements in this specification and in the Order.

13.7 Manufacturer is bound to replace or repair all valve parts which should result defective due to
in adequate engineering or to the quality of materials and machining.

13.8 If valve defect or malfunctioning cannot be eliminated, Manufacturer shall replace the valve
without delay.

13.9 Any defect occurring during the period of Guarantee shall be attended to by making all
necessary modifications and repair of defective parts free of charge to the Owner as per the
relevant clause of the bid document. All expenses shall be to Manufacturers account.

14.0 Site Service/Site Visits by Experts for TAS .

14.1 ROSOVs (ESDVs): Valve Vendor shall depute expert service engineer/engineers to site, for co-
ordination with TAS contractor for complete integrated testing of the system & stroking of the
valves

15.0 Painting, Marking and Shipment

15.1 Actuated Valve assembly surface shall be thoroughly cleaned, freed from rust and grease and
applied with sufficient coats of corrosion resistant paint. Surface preparation shall be carried
out by shot blasting to SP-6 in accordance with Steel Structures Painting Council Visual
Standard SSPC-VIS-1.

15.2 Manufacturer shall indicate the type of corrosion resistant paint used in the drawings submitted
for approval.

13000121-HD-10129 22 of 57
15.3 All valves shall be marked as per API 609.The units of marking shall be metric except Nominal
Diameter which shall be in inches. Marking shall be done by die-stamping on the cover or on
the housing.

15.4 Valve ends shall be suitably protected to avoid any damage during transit. All threaded and
machined surfaces subject to corrosion shall be well protected by a coat of grease or easily
removable Rust Preventative material. All valves shall be provided with suitable protectors for
flange faces, securely attached to the valves. All valve openings shall be positively sealed by
suitable blanking plates or plastic plugs. Adhesive tape sealing of opening without blanking
plates or plugs will not be acceptable.

15.5 All sealant lines and other cavities of the valve shall be filled with sealant before shipment.

15.6 Packaging and shipping instructions shall be as perAPI609 and procurement documentation.
Packaging shall be in accordance with the Project packing Specification.

15.7 All valves shall be transported in the fully close condition

15.8 On packages, following shall be marked legibly with suitable marking ink:

a) Order Number

b) Manufacturers Name c) Valve size and rating

d) Tag Number at least on 3 sides of packing, legible from distance.

e) Serial Number


16.0 Storage

16.1 Valves and components must be stored under cover and out of contact with the ground and
SHALL NEVER BE EXPOSED TO WETTING BY SALT WATER OR SALT SPRAY.





13000121-HD-10129 23 of 57
DATA SHEET VALVE
1. Valve Size

As per BQO


DESIGN PARTICULARS

2. Valve Type

Triple Offset high performance , metal to
metal seated, non-rubbing, torque seated,
double flange end, quarter turn, anti-
static, anti-blow out stem arrangement
butterfly valve. Complete actuated valve
shall be minimum SIL2 capable certified
by third party agencies like TUV/Exida

3.

Mfg. Standard

API 609

4 Face to Face

As per API 609, Long Pattern/ASME B
16.1

5 Inspection and Testing

API 598

6 Fire Safe API 6FA/API-607-Vth Edition,
Zero leakage before, during
after fire.
API 6FA/API-607-Vth Edition, Zero
leakage before, during and after fire.

7 ANSI Class

150#

8 Rated Travel

90 Degrees

9 Flow direction

Bi-directional, tight shut-off in either
direction

10 Fire Safe

Required

11 Anti Static Device

Required


CONSTRUCTION

12 Body

Cast (in Single Piece)

13 Disc

Cast
13000121-HD-10129 24 of 57
14 Stem Bar-forged (No
casting)
Bar-forged (No casting)

15 End Connection

Double flanged as per ANSI B 16.5RF

16 Flange & finish

150#, RF, 63-125 AARH, smooth finish

MATERIAL

17 Body

ASTM A216 Gr. WCB

18
19
Disc
Seal Ring

ASTM A216 Gr. WCB/ASTM A105

UNS S 31801/31803 Duplex SS+
Graphite

20 Stem/Shaft

ASTM A182F6a/ASTM A 479

21 Bushing

UNS S31600

22 Disc Retainer Flange

ASTM A 516

23 Disc and Bottom Flange

UNS 31600+Graphite

24 Seat

Stellited Gr. 21 Weld Overlay

25 Pin/Nut/Washers

SS 316

26 Thrust Bearing

SS 316/ Hardfaced /Cobalt based alloy

TESTING

27 Body Hydro-test

1.5 times the flange rating (30 bar #150)

28 Seat Hydro-test

22 bar #150, test duration as per standard

29

Pneumatic Seat

NA (6 bar #150) inline with API 598

Test


30 Leakage Class required

Zero Leakage/ bubble tight shutoff

SPECIAL REQUIREMENTS

13000121-HD-10129 25 of 57

General Notes:

1. BTS: Bidder to Specify
2. Approved makes for Air Filter: Norgren, Festo, SMC, Legris
31 Safety Integrity Level

Minimum SIL2 capable for actuated
valve when it is Type A Device

32 SIL Certification Std.

IEC 61508

33 Third Party Certification

TUV/Exida

ACCESSORIES FOR ROSOV

34 Dust Excluder

N.A.

35 Quick Exhaust Valve

N.A.

36 Fire Safe Box

N.A.

37 Volume/ Buffer Tanks

N.A.

38 Port Protector

N.A.

39

Pilot Valve

N.A.

40 Make & Model

BTS

41 Weight in kgs



BTS

PROCESS DATA

42 Design Pressure

As per #150

43 Design temperature

-5 to +65 55 deg. Centigrade

44 Fail Action

Fail to Close

45 Valve Torque+25%
safety margin

BTS

13000121-HD-10129 26 of 57
3. Approved makes for Proximity limit switches: Honeywell, Topworks
4. Approved makes for Pneumtic fittings & tubes: Swagelok, Sandvik, Parker
5. Approved makes for Exhaust Valve: Scradder, SMC, Festo, Legris



13000121-HD-10129 27 of 57

DATA SHEET ACTUATOR (Pneumatic)
1 Sizing basis 1.25 times the valve torque for shut-off
pressure and less than valve stem shear
torque
DESI GN PARTI CULARS
2 Actuator Type Pneumatic , spring return, air fail to
close, quarter turn, self-lubricating type,
suitable for TOBV on-off control,
complete actuated valve shall be
minimum SIL2 capable when classified
as Type A device, certified by third party
agencies like TUV/Exida
Scotch & Yoke design for valves of all
sizes
Minimum SIL2 capable when classified
as Type A device
3 Spring action Close (Air Fail to close)
SCOTCH & YOKE (CONSTRUCTION/ MATERI AL)
4 Housing Carbon steel
5 Yoke Carbon Steel
6 Yoke Bearing Bronze
7 Guide Block Alloy Steel
8 Guide Bar Alloy Steel
9 Guide Block Bearing Steel+ Bronze +PTFE
10 Travel Stop Screw Carbon Steel
11 Piston Carbon Steel
12 Piston Rod Alloy Steel
13 Piston Rod Seal NBR Rubber
14 Piston Rod Bearing Steel + Bronze +PTFE
15 Piston Seal O Ring NBR Rubber
16 Cylinder Carbon Steel
17 Cylinder Seal O Ring NBR Rubber
18 Tie Rod Alloy Steel
19 Spring Carbon Steel
20 Spring Container Carbon Steel
21 Guide Rod Alloy Steel
22 Container Rod Alloy Steel
23 Rod Bearing

Steel + Bronze+ PTFE
13000121-HD-10129 28 of 57
AI R SUPPLY
24 Max Allowable
Pressure
10 kgs/ sq cms (g) Min. Pressure 4.0
kgs/sqcms (g)
25 Available Air Supply 4.5 to 6.5 kg/sqcms (g)
26 Pneumatic Tubing size SS 316, 0.049 thickness
OTHER
27 Orientation 90 deg. To pipeline axis
28 Stroke Time Open & close : min 30sec max 60 sec
29 Hazardous Area
Protection
Zone 1, Gr. IIA/IIB, T3
30 Ingress Protection IP 65 as per IEC 529
ANCI LLARI ES
31 Air Filter Regulator Metal body, 5 micron gauge, SS tubing
and auto drain
32 Solenoid Valves As per SV Data Sheet
33 Valve monitor Required
36 Air Relief Valve Not required
37 Local Field Panel Required
38 Limit Switches Micro switches -SPDT, 2 nos for each
ROSOV,
Contact rating: 230 V AC/ 24 V DC
Operation.
IP 65, Die Cast Aluminium, 2 cable
entries with certified plugs
39 Make & Model BTS
40 Weight in kgs BTS
41 Air Consumption BTS in Ltrs (for one cycle Open-Close-
Open)
42 Approved makes Rotork, Biffi, Neles, Adams,Emerson

13000121-HD-10129 29 of 57
Notes:

1. Field Push button outside the dyke required for closing of the valve

2. Based on closing time requirement, bidder shall provide flow control valve in actuator
vent and with suitable locking arrangement applied after proper setting.

3. These ROSOVs are part of SIS and used as Emergency Shut Down Valves for tank overfill
protection. Complete actuated valve assembly shall be SIL3 capable as per IEC 61508,
certified by third party agencies like Exida/TUV. To calculate PFD (AVG) , the ESDV PFD
and SFF is required. Bidder shall submit the same with the technical offer along with
third party certifications and Functional Safety Manual.

4. All accessories like SOV shall also be SIL3 capable. Individual SIL certification shall be
submitted.

5. The actuator shall incorporate a safety feature such as a spring cartridge to prevent the
accidental release of spring tension during servicing. The actuator spring shall be fully
enclosed in a metal housing and permanently treated to resist atmospheric corrosion.

The type of treatment shall be manufacturers standard unless otherwise stated.
Cadmium or zinc plating (galvanizing) of actuator spring is not permitted.

6. Instrument Air filter with pressure gauge shall have built-in relief suitable for 10
kgs/sqcms to prevent over-pressurization.

7. At no time shall a pressure regulator or any other means be used to limit/reduce
actuator torque. The actuator shall withstand the maximum allowable air supply
pressure.

8. Actuator design shall be self-lubricating type








13000121-HD-10129 30 of 57
DATA SHEET SOLENOID VALVE

1 Quantity One for each ROSOV
GENERAL
2 Valve Type 3/2 Direct acting universal type,
suitable for fail safe operation (de-
energised to trip), SIL2 Certified
having capability for use in SIL 3
application.
3 Fluid Instrument Air
4
`
Fluid Data


a. Inlet Pressure
Min./Max.
b. Design Pressure
(Shutoff diff.)
c. Flow
d. Temperature






4.0/7.5 kgs/sq.cms.
10 kgs/sq.cms
BTS
65 55 Deg. Centigrade





5 Humidity 95% Relative Humidity
6 Area Classification Zone 1, Gr. IIA/B, T3
SOLENOID VALVE DATA
7 Type- Operation 3 way Universal
8 Action Direct
9 Body Size BTS
10 Port BTS
11 End Connection NPTF
12 Body Material SS316
13 Trim Material SS316
14 Packing-soft seals PTFE
15 Enclosure Protection IP 65, Flameproof-Zone 1, IIA/B, T3
Certified
17 Type of Energisation Continuous
13000121-HD-10129 31 of 57
18 Power Supply
a. Operating Voltage-
Energisation
b. Drop Out Voltage
c. Power Consumption

230 V AC / 50 Hz


BTS
BTS

19 Coil
a. Type of Coil
b. Style of coil

Single-Suitable for specified Haz. Area
Class

c. Insulation class
d. Cable Entry
e. Cable Gland
f. Terminals
g. Other wetted parts
h. Leakage

Standard
Class F or better as per IEC60085/IS1271
NPT(F)+Plug
SS 304, double compression
Internal for 2.5sqmm conductors
Vendors design
Zero Leakage

SPEC. ACC.



20 Mounting

Solenoid valves with mounting brackets
21 Name Plate

SS 304

22 Documents-
Catalogue/Manual

Installation/ Operation instructions to be
supplied


23 Certification

CCOE/CMRI type approvals to be
submitted
24 SS tubing

As required

25 Cable
glands/Reducers/Plugs/S
hrouds

Shall be supplied suitable for haz. area
classification


26 Approved makes for
SOV

ASCO/ Herion (Norgren)



Notes:
13000121-HD-10129 32 of 57

9. Suitable anti-vibration terminal blocks shall be provided for cable terminations. Terminals
shall be clip-on type (screw less), Phoenix/ Wago make

10. Flameproof Nickel plated brass, double compression cable glands shall be provided.
Cable glands shall be covered with shroud. Extra cable entry shall be plugged with
suitable E Exd Plug.




































13000121-HD-10129 33 of 57

Technical specifications Electro hydraulic actuators


1.0 SCOPE

1.1 This specification covers the requirements for designing, manufacturing, testing &
supply of Failsafe Actuator for Remote Operated Shut Off Valve (ROSOV). The actuator
shall have local integrated control unit for opening /closing of valves with open/close
indications and other essential monitoring and diagnostics indications and controls. It
shall have facility for non-intrusive setting of controlling and diagnostics parameters.

1.2 The actuator controls (Close only) and indications (open/close) are also to be provided
in a separate flameproof control station l (To be mounted away from actuator outside
tank dyke wall by the owner). The actuator shall also have provision for close from
Owners Control Room PLC/DCS.

1.3 The Electro Hydraulic actuator assembly shall be SIL-2 certified and / or capable for
standalone to use in SIL 3 applications.

1.4 The specifications as detailed are minimum requirement and shall be available in the
offered actuator model, make & wiring diagram as mentioned in the Actuator Data
sheet.

1.5 The specification for Actuator shall be read along with specification for Remote
Operated Shut off Valve and this specification together is deemed to cover complete
unit of Electro-hydraulic actuator of ROSOV.

1.6 Vendor is required to select the Actuator Model number, rating & various control
features as per the requirement of the valve. Accordingly the selected actuator type,
model and its control with wiring diagram number, shall ensure the operation of the
valve with the desired control.

1.7 Only one make of the actuator (for each type, size and rating of the valve) is to be
selected and freezed while submitting the offer.

2.0 CODES AND STANDARDS


The equipment shall comply with the requirements of latest revision of the following standards
issued by BIS (Bureau of Indian Standards) unless specified otherwise:

IS 9334 Electric Motor Operated Actuators
IS 13947 (Parts 1, 3, 4&5) Low Voltage Switchgear
13000121-HD-10129 34 of 57
IS4722 Rotating electrical machines
Specification
IS-325 Three-phase Induction Motors
IS 2148 Flameproof enclosures for electrical
apparatus
IS 4691 Degrees of protection provided by
enclosure for
EN 50018 Electrical Apparatus for Potentially
Explosive
Atmosphere [EEx(d)]
API RP 500 C Recommended Practice for
Classification of Locations for
Electrical Installations at
Petroleum Facilities Classified as
Class I, Division I and Division 2
IS 5572 Classification of hazardous areas (other
than mines) having flammable gases and
vapours for electrical installation
NEMA 6 Enclosures constructed for either indoor
or outdoor use to provide a degree of
protection to personnel against incidental
contact with the enclosed equipment
IEC 529 Classification system for the sealing
effectiveness of enclosures of electrical
equipment
BS 5501 Electrical apparatus for potentially
explosive atmospheres
IEC 60079 Electrical apparatus to explosive gas
atmosphere.
IEC 60529 Classification of degrees of protection
provided by
Enclosures (IP codes).
IEC 60801 Electromagnetic compatibility of
Industrial-Process
management and control equipment
IEC 61508 Functional Safety of
Electrical/Electronic/
Programmable Electronic Safety Related
Systems
IEC 61511 Functional safety ---- Safety
Instrumented Systems for
the Process Industry Sector


13000121-HD-10129 35 of 57

2.2 In case of imported equipment, the standards of the country of origin shall be applicable
if these standards are equivalent or more stringent that the applicable Indian standards.

2.3 The equipment shall also conform to the provisions of Indian Electricity Rules and other
statutory regulations currently in force in the country.

2.4 In case Indian standards are not available for any equipment, standards issued by IEC/
BS/ VDE/ IEEE/ NEMA or equivalent agency shall be applicable.

2.5 In case of any contradiction between various referred standards / data sheets and
statutory regulations, the following order of decreasing priority shall govern:

- Statutory regulations
- Data sheets & J ob specifications
- Codes and standards
- Manufacturers standards

2.6 The actuator and its associated materials/parts shall be designed, manufactured &
tested conforming to latest editions of the applicable Indian Standards and / or API RP,
including the standards as per Annexure VI, except where it has been modified and/or
supplemented by these specifications.

3 VENDOR REQUIREMENTS

3.1 The Vendor should provide the actuator of Specified Make only.

3.2 The vendor shall provide confirmation of spare parts availability from the actuator
manufacturer for the next 15 years.

3.3 The offered Actuator make /model shall have proven track record for its satisfactory
working for atleast last 2 years

4 TECHNICAL SPECIFICATIONS

Each actuator unit shall include the motor, hydraulic pump, hydraulic manifold,
accumulator, in-built safety system, pressure sensor indication of hydraulic oil pressure
along with position indicators, limit switches, electrical & hydraulic controls, terminal box
etc. as a self-contained unit. The actuator shall be sized to provide adequate torque
and/ or thrust to ensure the complete intended travel of the valve under the extreme
operating conditions.




13000121-HD-10129 36 of 57
The actuator unit shall be double sealed type, watertight and dustproof conforming to
IP65 minimum. Any electric/electronic parts inside the actuator assembly shall be
adequately protected and suitable higher rating of degree of protection shall be
provided.

The body of actuator assembly shall be of anodized aluminum and all piping to be of
SS316. All the fittings shall be of Swagelock/Parker only.

Enclosure shall be rated explosion proof Ex d and suitable for installation in Zone
1IIA/IIB, Temperature Class T3 electrical area classification. The actuator shall be sized
to guarantee valve closure and provide sufficient thrust to position and fully stroke the
valve against the maximum differential pressure that may develop under the specified
process and/or start-up conditions. Particular attention shall be paid to unbalanced
dynamic forces on the valve disc. For actuator sizing, the shutoff differential shall be
considered at full differential pressure. The full differential pressure for actuator sizing
shall be assumed as the maximum upstream pressure with the valve fully closed and
downstream pressure as atmospheric.

The operating speed for valve closing and opening rate shall be at approximately 1-2
second per inches size of the valve.

Two selector switches (lockable) shall be provided on the actuator, one for
Local/Stop/Remote selection, and with pad-lockable for each position and the other for
Open, Close and Stop Commands.

Electronic latching shall be provided for the torque sensing system to inhibit torque off
during unseating or during starting in mid-travel against high inertia loads. A jammed
valve protection circuit shall de-energize the motor after a few seconds, if no movement
occurs after receipt of a signal to open or close.

A local LCD display shall be provided for monitoring continuous indication of the
actuator position.

A separately sealed compartment containing segregated power and control terminals
shall be provided. Earthing terminals shall be provided at the external of ROSOV.

4.1 Actuator Torque Requirement

Actuator design torque shall be based on maximum valve pressure rating ANSI Class #150 at
design temperature and additional safety margin of 25% (1.25x). It actuator shall be capable of
opening the valve with the maximum differential pressure across the valve (equal to the maximum
specified design pressure on one side and atmospheric pressure on the other side).
It shall be based on a valve torque test as defined in API 6D, Appendix-C.

VALVE ACTUATOR
13000121-HD-10129 37 of 57
1. (Start-to-close torque)/
(Start-of-stroke torque
close)/
(Open-to-close break
torque)
Spring-start-torque (SST)
A safety margin of 1.25 x
shall be applied on top of
the valve start-to-close
torque. (i.e. 25% more)
2. Running Torque Spring-running-torque
(SRT).
A safety margin of 1.25 x
on top of the required
valve running torque shall
be maintained. (i.e. 25%
more)
3. Reseat Torque/
(Closing torque)/
(End-of-stroke torque)
Spring-end-torque (SET)
A safety margin of 1.25 x
on top of the valve closing
torque shall be applied.
(i.e.
25% more)

The Bidder shall specify maximum actuator torque. The Bidder shall specify and tabulate in his
quotation the required torque figures for each valve and the delivered torque figures by the. The
torque values shall be expressed in Newton meter (N-m) and shall be given for the following valve
positions:


o Start to open torque (breakaway torque)
o Lowest running torque during opening of the valve
o End of opening torque (valve fully open)
o Start to close torque (breakaway torque)
o Lowest running torque during closing of the valve.
o End of closing torque (reset torque, valve fully closed).

Bidder shall mention in the offer the values of the torque for

Va lve s te m s he a r torque .
Ma ximum torque output of a ctua tors .



5 ACTUATOR UTILITY

5.1 The Actuator shall be suitable for the following valve:

13000121-HD-10129 38 of 57

a)

Type of Valve Triple Offset Butterfly
Valve
b)

Size of valve Various Sizes
c)

Valve design As per specific
requirement
d) Valve Pressure Rating As per specific
requirement
e) Installation Outdoor

g)

Location of FLP
Control panel
Outside tank dyke wall

h)

Location of Owner
Control panel
Control building


6 GENERAL REQUIREMENTS

6.1 Summary
The Actuator shall be suitable for continuous operation under the specified ambient &
service conditions.

The vendor shall provide a statement defining the availability, reliability and
maintainability of his equipment in relation to defined product lifetime expectancy.

Design of the Actuator should be such that inadvertent access to live parts is avoided.

Actuator shall be suitable for operating in tropical climate and under the ambient
conditions as specified.

The Actuator shall be new and specifically produced against the order.

The actuator shall be a electro-hydraulic unit complete with sealed hydraulic, electronic
and termination compartment.

The actuator shall be fail safe type. For fail safe operation, the actuator shall utilize
internal spring return mechanism for safe position on loss of power supply and/or ESD.

6.2 Area Classification

Actuator and separate control panel shall be suitable for Class-I, Division-I, Gas Group C&D as per
API RP 500 C or Class-I, Division-I, Gas Group - IIA & IIB as per BIS -5572 (Indian Standard).
13000121-HD-10129 39 of 57

6.3 Marking

The following shall be clearly marked on the nameplate of the actuator :
Name of the manufacturer :
Model No. : ::
Input Voltage :
Max torque (N-M) setting :
Gross weight :
Year of manufacturing :
Actuator tag number as per data sheet
Hydraulic oil pressure( Normal/Maximum)
Hydraulic oil Type
Area classification:

6.4 Enclosures

The actuator enclosure shall be explosion proof & weather proof suitable for mentioned area
classification. The actuator enclosure shall be supplied with fire proof jackets for fire safe operation.

The Actuator and the integrated control panel shall be watertight with double sealing conforming to
min. IP65 as per IEC- 529/BS5490.

Any electric/electronic parts inside the actuator assembly shall be adequately protected and suitable
higher rating of protection shall be provided.

The Actuator and control panel shall have flame proof designation as EEx(d) IIB T4 CENELEC
Norm EN50018,BS5501 certified by BASEEFA UK/ UL/ FM, USA/SIRA Italy.



6.5 Paint Finish

Actuator and control panel shall be epoxy painted suitable for exposure at location involving salt
spray, high humidity, temp range of - 200 5 deg C to +700 55 deg C.

The epoxy painting shall pass weathering test as per relevant British Standard.

6.6 Electric Motor

6.6.1 Actuator shall be suitable for the ac supply voltage of single (230V AC)/ three phase
(415 volt) +/- 10% variation at 50 Hz frequency with +/- 3% variation.

6.6.2 The motor shall have Class `F insulation with temp rise limited to class B.
13000121-HD-10129 40 of 57

6.6.3 Motor shall be housed in a totally enclosed non-ventilating type enclosure.

6.6.4 The motor shall be provided with stall detection device to stop the motor, if motor
operation is inhibited.

6.7 Auxiliary Contacts

6.7.1 The Auxiliary switch contacts shall have a minimum rating of 0.25A, 110V DC Non-
inductive.

6.8 Torque & Position Limit Settings

6.8.1 Open and Close position limit settings with adjustable selection shall be provided to
ensure correct valve travel.

6.8.2 The internal pressure shall be continuously monitored to prevent excessive torque.

6.8.3 Four limit settings, two at each end of travel for interlocking/ indication, shall be
provided.

6.9 Wiring and Terminals

All devices provided in the actuator shall be wired up to the terminal block. The contacts for remote
operation and indication shall also be wired up to the terminal block. Minimum 10% spare terminals
shall be provided for future interlocks. Internal wiring for power and control circuits shall be
appropriately sized for ROSOV actuator rating. Each wire shall be identified at both ends using PVC
ferrules. The terminal compartment shall be separated from the inner electrical components of the
actuator by means of a watertight seal so that the actuator electrical components are protected from
the ingress of moisture and foreign materials when the terminal cover is removed during installation
and maintenance. The different functional PCBs will be slot specific and non-interchangeable
among themselves to facilitate easy trouble shooting and replacement.

Vendor shall be solely responsible for the compatibility of the actuator with the valve and for the
selection and sizing of various electrical devices and components in the actuator.

The actuator shall be provided with minimum three adequately sized cable entries viz., one for power
cable and two for control cables. However, the actual number of control cable entries in actuator with
2-wire control system shall be provided based on job requirements as specified in data sheets/
specification for control systems for ROSOV Suitable double compression cable glands shall be
provided with each actuator for all cable entries and sealing plugs for all control cable entries. The
cable glands and plugs shall be made of Nickel-plated brass.



13000121-HD-10129 41 of 57
6.10 Conduit Entries

Party shall indicate offered conduit entries in NPT, as per standard design of
Actuator & control panel in the enclosed Data Sheet.

6.11 Cable Glands / Reducers

Double Compression Flame Proof, Explosion Proof & Weather proof CABLE GLANDS
with suitable reducers, shall be supplied. Spare entries shall be plugged with
Flameproof Weatherproof plugs

7 CONTROL FACILITIES

The control system shall have remote control facility as a standard feature. The remote control
circuits shall be powered from internally derived control supply voltage. It shall also have minimum
4 nos. of alarm status contacts indicating the availability of the actuator for remote control/indication
for monitoring of the following:
- Loss of one or more phases of power supply
- Loss of control circuit supply
- Selector switch in local mode
- Local stop push button set to Off
- Any other local fault/ abnormal condition

8 Emergency Shutdown (ESD)

ESD functionality shall be based on de-energized to trip condition.

ESD functionality shall be performed on actuation any of the following conditions.

Actuation of 24V DC remote command signal from Owners control system. This shall be
isolated from control electronics through opto-isolator.
Loss of main power.
Loss of hydraulic power
Actuation of local/remote push button.
Other conditions, as applicable for ESD.

ESD functionality shall close the valve even when the selector switch is on local mode.

After an ESD action, normal operation can be restored after normalization of the process and valve
opening or closing as the case may be only after resetting the system through resetting through the
local pushbutton, or depending upon the configuration

13000121-HD-10129 42 of 57

9 Field Control Unit:

The field control unit shall be integral to actuator and shall be powered from the actuator power
supply. It shall be configurable locally either with pass word protected in-built key pad or hand held
remote configurator. No separate power supply shall be provided for operation of field unit. In both
cases, setting of parameters, there will be no opening of covers, and use of any special tools or
instruments.

Two separate backlit 3&1/2 LCD displays will be provided for indication of actuator parameters and
configurations.

The field control unit shall be able to execute the following minimum operational commands:

Fully Open/Close the valve.
Emergency shutdown (Hardwired contacts from Owners PLC shall be provided for ESD
actuation)
Emergency shutdown (ESD) signal shall over-ride any other signal command .
Capability of 2-wire communication with Owners PLC (through master control station as
applicable).

10 Configuration Tool

10.1 The actuator shall have in-built facility for configuration and setting of safety
parameters.

10.2 If any external setting tool/ device is required for configuration of settings, the same
shall be offered with the actuator & FLP control panel. The external tool shall be
intrinsically safe for hazardous area operation.

10.3 One number of such tool per location shall be integral part of the offer and shall be
supplied along with the actuator and FLP control panel.

10.4 In case the configuration and setting is to be done from push buttons, no separate
external tool is to be offered.

11 INTEGRAL PUSH BUTTON, SELECTOR AND CONTROL DEVICES :

The following local control devices shall be provided integral with the MOV actuator:

a) Push buttons for Open/ Close selector switch shall be provided. OPEN & CLOSE push
buttons should be of green & red color respectively. Close operation shall be push type &
Open operation shall be press & rotate type

b) Local/ off/ Remote Selector switch shall be pad-lockable in each position.
13000121-HD-10129 43 of 57

c) Local continuous position indication from Valve fully open to Valve fully closed
position, which may be of analogue or digital type using mechanical indication/ Indicating
lamps /LEDs.

Also the ROSOV shall have provision for closing from Local Push button (Proposed to be provided
outside dyke wall)

12. TORQUE AND TRAVEL LIMIT SWITCHES :

The limit switches shall be preset. The switches shall be provided with requisite number of potential-
free contacts for valve actuator operation and for indication on remote panels as specified in data
sheet. Instead of mechanical torque limit switches, magnetic pulse counter / encoders to measure and
control the stroke of actuator may be provided, wherever this feature exists in manufacturers design.

13 Pressure Measurement

Internal pressure transducer shall be provided for monitoring the internal hydraulic system pressure
and provide alarm for potential stall condition of the valve. The signal of pressure shall be in %age of
maximum generated system or actual pressure in 4-20 mA current signal.

14 Two wire control System

MOV shall be suitable for two wire control system. This actuator shall have individual field units
connectable to master control station through a single 2 wire cable loop for control and monitoring.
The vendor shall indicate the maximum number of field units can be connected to a master station
and maximum distance from field unit to master station. The vendor shall also indicate maximum
number of control input and control/ status output from each field unit that can be handled through 2
wire control system.

The MOVs should either have General Purpose FCU card embedded for communicating to any make
of Master Station or the FCU should be compatible for direct communication on 'Open Type
International Standard 2 wire serial communication protocol/MODBUS for serial communication
directly. The following signals shall be available at the Control room:
-Valve open
-Valve closed
-Actuator fault
-Field unit fault
-Cable fault
-Monitor relay trip
-Thermostat trip
13000121-HD-10129 44 of 57
-Local stop selected
13000121-HD-10129 45 of 57
-Local Control selected
-Valve Obstructed
-Valve jammed

Remote control function shall be provided to permit the actuator to:
-Open fully
-Close fully
-Assume Emergency Shut Down position

Each field unit /MOV actuator shall be addressable from master control station through unique
address code. All the field settable / adjustable parameters of MOV actuator shall be settable from
master control room Similarly all the indication available on the MOV actuators shall be available at
the master control station. Full diagnostics feature of MOV shall be available on master control
room. Suitable redundancy shall be provided such that in case of fault in the cable, the field unit
continues to communicate with the master control room.

16 Wiring and Terminals:

All devices provided in the actuator shall be wired up to the terminal block. The contacts for remote
operation and indication shall also be wired up to the terminal block. Minimum 10% spare terminals
shall be provided for future interlocks. Internal wiring for power and control circuits shall be
appropriately sized for ROSOV actuator rating. Each wire shall be identified at both ends using PVC
ferrules. The terminal compartment shall be separated from the inner electrical components of the
actuator by means of a watertight seal so that the actuator electrical components are protected from
the ingress of moisture and foreign materials when the terminal cover is removed during installation
and maintenance. The different functional PCBs will be slot specific and non-interchangeable
among themselves to facilitate easy trouble shooting and replacement.

Vendor shall be solely responsible for the compatibility of the actuator with the valve and for the
selection and sizing of various electrical devices and components in the actuator.

The actuator shall be provided with minimum three adequately sized cable entries viz., one for power
cable and two for control cables. However, the actual number of control cable entries in actuator with
2-wire control system shall be provided based on job requirements as specified in data sheets/
specification for control systems for ROSOV Suitable double compression cable glands shall be
provided with each actuator for all cable entries and sealing plugs for all control cable entries. The
cable glands and plugs shall be made of Nickel-plated brass.

17 REQUIREMENTS FOR HAZARDOUS AREAS:

Hazardous Area Classification and Protection: Instruments located in hazardous area shall be
certified to meet or exceed the electrical hazardous area defined by Area classification .
13000121-HD-10129 46 of 57
The actuator accessories used shall be flame proof and suitable for hazardous area of Zone 1,
Group IIA/IIB, T3 or better for applications. Additionally all valve associated instruments shall be
weatherproof to IP65./PI67/IP68 as applicable Instruments certified for use in the specified
hazardous area classification shall be recognized by authority like FM,CENELEC, PTB, BASSEFA,
ATEX , CCOE/PESO etc.

Actuators meant for hazardous areas shall meet the requirements of IS 2148, IEC 79 or equivalent
international standards . The manufacturer shall possess valid test certificates issue by a recognized
independent test house (CIMFR/ Baseefa/ LCIE/ UL/ FM or equivalent) for the offered actuators. All
indigenous equipment shall conform to Indian standards and shall have been tested and certified by
Indian testing agencies. All equipment (indigenous and imported) shall also have valid statutory
approvals as applicable for the specified hazardous locations from Petroleum and Explosives Safety
Organization (PESO)/ CCE or any other applicable statutory authority. All indigenous flameproof
equipment shall have valid BIS license and corresponding marking as required by statutory
authorities.

Apart from the nameplate indicating the Tag Number. a separate nameplate shall also be provided on
each actuator to indicate the details of the testing agency (CIMER or equivalent), test certificate
number with date, statutory approval number with date, approval agency (PESO/ CCE/ DGMS or
equivalent), BIS license number with date, applicable Gas group and Temperature class etc. the
nameplate shall be riveted/ fixed with screws and not pasted. In case any of the standard details listed
above are embossed on the enclosures, the same need not be repeated.

Actuator units shall be SIL-2 certified and shall be capable for standalone use in SIL 3 applications,
having certification conforming to IEC 61508 / IEC 61511 from TUV/Exida or other accredited
international agencies.

18 INSPECTION, TESTING AND ACCEPTANCE :

The equipment shall be subject to inspection by Owner or by an agency authorized by the owner.
Manufacturer shall furnish all necessary information concerning the supply to Owner. During the
course of manufacturing, the purchaser or his authorized representative shall be free to visit the
works and assess the progress of work and the manufacturer shall render him all possible assistance
to do so.

Following routine and acceptance tests shall be carried out at the manufacturers works under his
supervision and at his own cost for all the actuators in line with QAP approved by the owners.

a. ROUTINE TEST : Functional and calibration test for torque and limit switches



b. ACCEPTANCE TESTS :

Response time test
13000121-HD-10129 47 of 57

Variation of supply voltage

Variation of frequency

Tests for motor (As per relevant IS/ IEC)

Test on output shaft

Any other test as applicable

19 FOLLOWING TESTS SHALL BE PROVIDED PRIOR TO SHIPPING:

Actuator operation, Cycle (open-close) each valve with its actuator at least five
times, for proper actuator operation. Verify that valve position coincides with position
indicators.
Opening -closing position
Actuator output speed & Open-Close time
Actuator travel setting
Operational torque test as per API 609. The maximum measured torque shall be
less than 75 % of the design torque specified by the valve manufacturer for actuator
sizing.
FAT and SAT for the system

Two weeks notice shall be given to Owner for witnessing the final testing of the complete
assembly to ensure satisfactory operation of the actuators. Type test certificates shall be
furnished with bids. Final acceptance of ROSOV at site shall be subject to successful
testing of the actuators with the valves.

Type test certificates, original drawings referred in certificates and statutory approval
certificates and BIS license, where applicable, shall be shown to the inspection agency on
demand. The certificates and BIS license must be valid at the time of dispatch.
Test certificates of bought-out components shall be shown to the inspection agency on
demand.

20 PACKING AND DISPATCH :

All the equipment shall be divided into multiple sections for protection and ease of handling
during transportation. The equipment shall be properly packed for the selected mode of
transportation, i.e. by ship, rail or trailer. The equipment shall be wrapped in polythene
sheets before being placed in crates/ cases to prevent damage to finish. The crates/ cases
shall have skid bottoms for handling. Special notations such as Fragile. This side up,
Center of gravity, Weight, Owners particulars, PO no. etc. shall be clearly and indelibly
marked on the packages together with other details as per purchases as per purchase
order.
13000121-HD-10129 48 of 57

The equipment may be stored outdoors for long periods before installation. The packing
shall be completely suitable for outdoor storage in areas with heavy rains and high ambient
temperature unless otherwise agreed. In order to prevent movement of equipment/
components within the crates, proper packing supports shall be provided. set of instruction
manuals for erection, testing and commissioning, a set of operation and maintenance
manuals and a set of final drawings shall be enclosed in a waterproof cover along with the
shipment.

These precautions shall be read in conjunction with similar specifications for valves.

21 SPARES & SPECIAL TOOLS :

21.1 Vendor shall submit list of standard spares of Actuators along with unit rates with
validity for 2 years.

21.2 Vendor shall submit list of special tools, if required for maintenance of Actuators along
with unit rates with validity of 2 years.

The above shall be submitted in a separate sealed envelope as mentioned in the
price-bid formats

22 COMMISSIONING ASSISTANCE :

Vendor shall arrange to depute his commissioning engineer to Bhartpur as covered in
Purchase order for supervising commissioning activities of actuators without any extra
charges. The representative shall ensure that the actuator is commissioned successfully.

23 WARRANTIES:

23.1 Vendor shall provide warranty for the performance of Actuators for 18 months from
date of dispatch or 12 months from date of installation, whichever is later.

23.2 In addition, vendor shall also include comprehensive extended warranty of 3 years
commencing from the date of expiry of warranty as per clause 10.1 as above

23.3 During the entire warranty period as above vendor shall carry out the preventive
checks(half yearly visits) besides attending to break downs within a period of 72 hours.
The scope of the vendor shall also include the spares, tools & tackles etc., visit of
service personnel and other travelling/boarding expenses replacement of defective
parts free of cost, if any. However , suitable assistance(un skilled labour and lifting
tools )if any , required for attending the service/repairs will be provided by the owner.



13000121-HD-10129 49 of 57
24 DATA SHEET FOR ROSOV ACTUATOR : PURCHASERS DATA

24.1 SITE CONDITIONS

S.NO.
1.1 Altitude Less than 1000 m Above
MSL
1.2 Design ambient
temperature
- 1 deg. To + 55 deg. C
1.3 Humidity max. 100 %
1.4 ROSOV Tag Nos Will be intimated after
award of contract.


24.2 SYSTEM CONDITIONS :

S.NO.
2.1 Supply Voltage 415V+10%, 3-phase AC
for ROSOV
2.2 Supply Frequency 50 Hz +3%
2.3 System Earthing Solidly Earthed


24.3 OPERATING ENVIRONMENT :

S.NO.
3.1 Area Classification : Zone 1
3.2 Gas Group : IIA/IIB
3.3 Temperature Class : T3
3.4 Construction : Flameproof Ex(d)
3.5 Ingress Protection : IP65
3.6 Painting : Epoxy base
3.7 Fire proofing required : No
3.7.1 For ROSOV Tag Nos : Not Applicable.
3.7.2 With fireproof rating : Not Applicable
4.0 Valve Duty , Mode of Control and Devices for Control
4.1 Valve duty

:
Fully open and fully closed Yes.
. Partially open and partially closed No


Control Requirement Local & Remote
for all ROSOVs
Setting adjustable parameters of Actuator (
for 2 wire control system)
From field & remote thru
Master Control Station /
13000121-HD-10129 50 of 57
PLC for 2 wire control

Continuous position indication


Local

Mechanical / Digital
indication is required.

Remote Potentiometer / transducer for
remote continuous indication

Required in control room
thru Master Control
Station

Intermediate travel limit switch Required

Potentials free contacts for indication on
remote panel and other interlocks

For Valve Open Position

Required

For Valve Closed Potion Required

For remote indication or position of Local /
Remote selector switch
Required

For availability of ROSOV actuator Remote
Operation ( contact from monitoring relay)
Required

Remote emergency stop push button for
Stopping Actuator
Required

DCS/PLC interface for Remote Control /
Indication
Remote Indication
required for all ROSOVs

Indication Required

Open/Close Limit Switches Required

Time of operation
- Opening & closing Min 30 sec Max 60 sec
Make of ROSOV Valve Actuator

Rotork, Biffi, Auma
Limitorque or equivalent

Double Compression Glands & plugs ( for
unused entries ) , to be supplied with the
Actuator

Flame & Weather Proof
MOC: SS316SS

Notes :
1. N.A. denotes Not Applicable.
13000121-HD-10129 51 of 57

2. Area Classification Zone, Gas group and Temperature class indicated at 5 Nos. 3.1 to 3.3
above refer to IS/IFC standards.

3. The purchaser shall provide single point power supply to the actuator as per S.No.2
above. Any other control supply voltage required shall be internally derived by the
manufacturer within the actuator.

4. Vendor shall furnish complete data as per Part-II of this data sheet for each ROSOV
Actuator along with the offer.

5. Remote Input signals for opening / closing / stopping the ROSOV shall be provided
through the momentary closing of separate potential free contacts in owners panel.

Necessary controls required for running the motor for the complete opening / closing
sequence of the valve using such input signals shall be provided by manufacturer in the
actuator.

25 Vendor data requirement ROSOV Actuator

S.No.

Description

With
Bids

Post order


For
Review

For Ref./
Records


1

Vendor Drawing /

* *
Document Submission
Schedule


2 List of deviations, if any,
to MR requirements


3 Data Sheets (duly filled in

* * *
4

5
G.A and mounting details
of actuators
Wiring and Connection
diagrams

*

*
*

*
6 QA Plan of Vendor

* *
7 Shop Inspection Plan and * *
13000121-HD-10129 52 of 57
Testing Procedure

8 Test Records

*
9 Type Test Certificates for
Flameproof / Explosion
proof equipment

* *
10 Recommended
maintenance spares with
prices


11 Equipment storage
procedure

*
12 Data Books / Manuals



a. Installation Manual and
Standard
b. Operating/Maintenance
Manual
c. Catalogues / Brochures
indicating complete
technical details and data
for actuator selection





*
*

*

*
13 Details of fireproofing, if
specified in data sheet

* * *

Notes :

1. Vendor shall furnish soft copy of all drawings in Auto Cad version 14.0/ 2000 and all
documents in MS Office 2000, as part of final documentation.

2. All technical details and documents furnished with bids shall be treated as data for
engineering. These shall however, be subject to Purchasers review after order
placement and bidder shall comply to MR/Tender requirements without any cost & time
implication.

3. Vendor shall submit detailed functionality and Single Line Diagram of the Actuator along
with the Technical Bid.

13000121-HD-10129 53 of 57







QAP
13000121-HD-10129 54 of 57
QAP for TRIPPLE OFFSET BUTTERFLY VALVE
SCOPE OF
INSPECTION
S
.

N
o
.

S
T
A
G
E
/

A
c
t
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v
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t
y

C
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C
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A
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M
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C
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Q
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A
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A
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S

R
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V
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V
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/

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1.
I
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c
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m
i
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g

M
a
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C
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s
t
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g

&

f
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i
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(
v
a
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e

b
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y
,

D
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,
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r
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g
s

,

s
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,

b
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)




Surface Quality Visual As per Mfg Test
plan & applicable
code
As per Mfg
Test plan &
app. code
As per Mfg
Test plan &
app. code
Inspection
Report
P R R
2. Dimensions Measurement

As per Mfg Plan Appr.
Drg.

Appr. Drg. Inspection
Report
P P R
3. Chemical & Mech.
Properties

Review of
Vendor
TC
All Heats As per
relevant
Material
Spec
As per
relevant
Material
Spec
TC P R R
4. All casting
materials
Heat Treatment as
per specs

Review of
HT
All Lots Relevant
Std./Material
Spec.
Relevant Std./
Material Spec.
TC P R R
5. Body
Casting
Radiography
Examination

Radiography 100% of qty.

Relevant
Std./Mat Spec.
Relevant Std./
Material Spec.
Film
&
report
P R R
6. Bars for trim
material
Chemical analysis Lab Check All heats Relevant
Std./Mat Spec.

Relevant Std./
Material Spec.
Lab report P R R
7. Overlay/
Stelliting
using
robotic
welding
machine

Valve body
seat ring
Thickness &
Hardness of
Overlay/Stelliting
Process
validation
One test
specimen per
material made of
base material
As per app.
code /spec.
As per app.
code /spec.
WPS &
WPQ,
PQR
- P R

13000121-HD-10129 55 of 57
QAP for TRIPPLE OFFSET BUTTERFLY VALVE
SCOPE OF
INSPECTION
8. Dimensions
checking
seal ring &
seat ring
Dimensions
checking of
using 3D
measurement
tool
One valve per
size
As per mfg std
or as per app.
code
As per mfg
std or as per
app. code
- P R



Inside
micrometer
100% of qty. P H
9.
B
o
u
g
h
t

O
u
t

F
i
n
i
s
h
e
d

&

S
u
b

c
o
n
t
r
a
c
t

i
t
e
m
s



S
t
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,

G
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Surface Defects Visual As per Mgf
Sampling
Plan
App DWG /
Relevant Std.
App DWG /
Relevant Std.
Inspection
Report
P R R
10. Dimension Measurement As per Mgf
Sampling
Plan
App DWG /
Relevant Std.
App DWG /
Relevant Std.
Inspection
Report
P R R
11. Physical &
chemical
properties
Review of TC of
supplier
As per Mgf
Sampling
Plan
App DWG /
Relevant Std.
App DWG /
Relevant Std.
Inspection
Report
P R R
12.
P
r
o
d
u
c
t

E
v
a
l
u
a
t
i
o
n

&

T
e
s
t
i
n
g








F
i
n
i
s
h
e
d

V
a
l
v
e










Pressure Shell
test
100 % of the
valves of all
sizes & types
As per app.
code /spec/drg.
As per app.
code /spec.
As per app.
code /spec.
Test
Report
- P W
13. Hydraulic Seat
Test at Closing
Torque of valve

100 % of the
valves of all
sizes & types
As per app.
code /spec/drg.
As per app.
code /spec.
As per app.
code /spec.
Test
Report
- P H
14. Anti-static testing
(if applicable)
1 valve of each
size & type
As per app.
code /spec/ drg.
As per app.
code /spec.
As per app.
code /spec.
Test
Report
- P W
15. Torque/thrust
functional testing
1 valve of each
size & type
As per app.
code /spec/ drg.
As per app.
code /spec.
As per app.
code /spec.
Test
Report
- P W
16. Drive train
strength test
1 valve of each
size & type
As per app.
code /spec/drg.
As per app.
code /spec.
As per app.
code /spec.
Test
Report
- P R
17. Fire Safe Test
(type Test)
As per app.
Code/spec./drg/
As per app.
code /spec./drg.
As per app.
code /spec.
/drg.
As per app.
code /spec.
/drg.
Test
Report
- P R
18.

Functional/
Operational
Test (For Motor
/Actuator
Operated)

As per DWG. 100% by vendor App DWG App DWG Test
Report
-----
-
P R
10% by
MECON/HPCL
P H
13000121-HD-10129 56 of 57
QAP for TRIPPLE OFFSET BUTTERFLY VALVE
SCOPE OF
INSPECTION
19.
F
i
n
a
l

I
n
s
p
e
c
t
i
o
n



Body , Seat
& Stem
PMI Check 10% by Supplier
& 1 valve of each
size & type by
MECON/ HPCL
at random
P R


20. Finished
Valve

Visual (TC
Verification, SL.
No. Marketing
Flange finish, Tag
No.) Bevel
Dimensions &
Special
Requirement in
PO
Visual:
100% &
at random
App DWG App DWG Inspection
Report
-----
-
P H
21. Packing Finished
Valve
------ At random 100% by supplier As per
dispatch
instructions
---- -----
--
P R

Legends: H-Hold (Offer for Witness & obtain clearance),W-Witness, R-Review, P Perform, A-Approval, I-Information, X-Submit, PO-Purchase Order, PR-Purchase
Requisition, Differential hardness surveillance check & to be taken up before lapping is done normally, , DP-Dye Penetrate Test, UT-Ultrasonic examination,
All the NDT-Leak testing/Heat treatment/Special manufacturing procedures have to be specially approved or only previously approved procedures have to be used. In
case of conflict between purchase spec., purchase spec. shall be applicable. This document describes generally the requirements pertaining to all types of valves.
Requirements specific to the item are only applicable.

Abbreviation:

WPS - Welding Procedure Spec.
WPQ - Welders Performance Qualification
PQR-Performance Qualification Report
QAP - Quality assurance plan
Mgf - Manufacturing
Spec- Spec.
App DWG - Approved Drg.
TC Test Certificate

Note: This QAP is to be further developed by Vendor & to submit for approval before manufacturing

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